BOILER EMERGENCY

OPERATIONS
BOILER EMERGENCIES – Various Emergency
situations during operation with a special emphasis
on the safety aspect like boiler protection systems
controls and interlocks
 Drum level lo and lo-lo
 Drum level high and high high
 Furnace Draft high and high high
 Flame Failure
 Boiler feed pump failure
 Boiler pressure high
 Furnace Explosion
 Water wall / screen tube / evaporator tube failure
 Coal feeder trip / burner trip
 APH tube failure
 Fan Failure
 Super heater tube failure
 High super heater temperature
 Low Super heater temperature
 Bed Temperature High
 Bed Temperature Low
 PA fan trip
 PSH O/L steam temperature high
 Economizer O/L FW temperature high
 High negative draught
 Hot bed material leakage from PA lines or bed ash drain
 O/L steam pressure too low
 Back fire in PA lines
 1. DRUM LEVEL LOW AND LOW-LOW

A. CAUSE :-
 Failure of boiler feed pump.
 Failure of drum level controller.
 Inadvertent opening of C.B.D.
 Extraordinary change in load.(Sudden reduction in load)
 Water tube failure.

B. EFFECT:-
 Boiler may damage badly.
C. ACTION:-
 Run the boiler if drum level is within safe limit (Lo alarm
and lo-lo alarm came). If it goes beyond safe limit allow
boiler to trip.
 Check FW control valves position in DCS and in field, if
feed valve is stuck up open parallel line valve or bypass
valve.
 Take care while increasing feed flow that running B.F.P.
do not trip on feed flow high.
 If low level is due to tripping of feed pump start stand by
pump, if it is on manual.
 Check position of all MOVs and operate them
accordingly.
 Check for any abnormal sound from furnace.
 If water level is below safe level, allow to trip the boiler
on drum level lo-lo to protect the boiler drum and tubes.
 2. DRUM LEVEL HIGH AND HIGH HIGH :-

A. CAISE
 Failure of drum level controller.
 Extra ordinary increase in load
 Sudden increase in firing rate.

B. EFFECT:-
 Water may enter turbine and serious damages to turbine may
occur.
 Joint valve on main steam pipe work leaks.
 Carry over with sharp fall in super heater temperature
C. ACTION :-
 Run the boiler if drum level is within safe limit (drum level
high and high high alarm came). If goes beyond limit allow
boiler to trip.
 Attempt to control with feed valve.
 Check FW control valves position in DCS and in field, if feed
valve is stuck up close isolating valve.
 Attempt to control drum level by opening C.B.D.
 Close Economizer inlet valve as per requirement and allow
feed pump to run in Recirculation.
 If above measures fail trip the feed pump.
 If level is due to sudden rise in load. If high level rises above
normal level – allow boiler to trip on drum level high high.
 Operate IBD as per requirement...
 Observe Final steam temperature and if it starts dropping,
close Boiler stop valve immediately.
 3. FURNACE DRAFT HIGH AND HIGH HIGH
A. CAUSE :-
 Due to faulty operation of fan control.
 Disturbed combustion
 Un-controlled fuel entry
B. EFFECT:-
 Boiler may damage due to high furnace pressure.
 Weak parts of furnace (ducting and enclosures) may explode
due to high furnace pressure.
C. ACTION :-
 Confirm that the draught indication is correct.
 If it is due to faulty operation of I.D./P.A./S.A. fan control,
take it on manual and maintain the furnace in suction.
 If furnace pressure has increased beyond limit allow boiler to
trip on furnace draught high high.
 4. FLAME FAILURE :-
A. CAUSE :-
 Dirty Oil Burner
 Furnace Pressure High
 Low Combustion Air
B. EFFECT :-
 Boiler will trip on flame failure
 Chances of furnace explosion, if unburnt oil / coal mixture entered in
furnace.
 Boiler steam pressure may fall down.
 Super Heater Steam Temp. drop sharply.
 Variation observed in drum level. (drum level low)
C. ACTION :-
 Purge the boiler before putting burner back and purge burner as per
cycle time given by supplier.
 Clean the burner tip, if nozzles (holes) are found chocked.
 Check the air fan and maintain air fuel ratio.
 Check the explosion doors, close it if opened.
 5. BOILER FEED PUMP FAILURE :-

A. CAUSE :-
 Motor protection relay operates
 Lube oil temperature high
 Discharge flow high
 Motor bearing temperature high

B. EFFECT :-
 If standby pump is available, it will start on auto or start it
manually.
 If standby pump does not start on auto & manual, drum level
may go very low, which may trip the boiler.
C. ACTION :-
 Start the stand by pump, if it does not start on auto. Adjust the
load to maintain the drum level as well as to prevent the
tripping of this pump on high feed water flow.
 See the proper operation of recirculation valve and C.W.
Valve.
 Analyze and rectify the fault in the main feed pump. Put it on
auto.
 Restore the bus supply, if it has lost and make the pump
available.
 Monitors drum level (Increase dumping CV opening, if drum
level starts dropping).
 If both the BFP tripped and standby has not taken over
because of any common problem, trip both TG and box – up
the boiler.
 6. BOILER PRESSURE HIGH

A. CAUSE :-
 Sudden drop in load / steam flow.
 Un-controlled fuel entry.
 Turbine / prime mover trips.
B. EFFECT :-
 Disturbance in drum water level.
 Safety valves may life if pressure rise is up to that extent.
 Boiler may trip on high pressure.
C. ACTION :-
 Open start up vent valve.
 Control fuel input and drum level.
 Check coal feeder feeding rate.
 Adjust the load on unit, if it has dropped.
 7. FURNACE EXPLOSIOIN

A. CAUSE :-
 Accumulation of unburnt fuel during light up / start up of
boiler.
 Improper burning.
 Inadequate air.
 Secondary combustion.
B. EFFECT :-
 Furnace explosion can cause extensive damage.
C. ACTION :-
 Always purge the boiler with 40% full load air for about five
minutes. No cut short in purging allowed.
 Adjust fuel air ratio.
8. WATER WALL / SCREEN TUBE / EVAPORATOR
TUBE FAILURE

A. CAUSE :-
 Starved water wall.
 Block tube, eroded tube, pitted tube, salt deposits.
 Circulation affected due to open low point drains.
B. EFFECT :-
 Hissing steam leakage noise from boiler.
 Unstable flame fluctuating draught.
 Bed temperature drops sharply.
 High feed water flow for given steam generation / increase in
make up water.
 Increase in I.D. Fan loading.
 Below screen temperature drops sharply.
 Flue gas outlet temperature decreased.
C. ACTION :

 Every shift check low point drain valve are fully closed.
 Every shift check the furnace listen furnace to detect steam
noise.
 At first diagnostics of tube failure, start load reduction; trip
out unit before damage become serious. Quicker shutdown
reduces extensive damage.
 Try to locate tube at low load .
 Don’t allow the drum level to go beyond a danger level.
 Start another BFP, if drum level is not maintained by
running BFP.
9. COAL FEEDER / BURNER FAILURE :-
A. CAUSE :-
 Electrical supply failed
 V.F.D. fault
 Bed temperature high
 Furnace draft high
 Furnace draft low
 Drum level high
 Drum level low
B. EFFECT :-
 Boiler pressure may fall down
 SH steam temp fall sharply.
 Bed temp. will decrease.
 Variation in furnace pressure (LOW)
 Variation in drum level (Low)
C. ACTION :-
 Increase feeding in other compartments or boiler.
 In case of any one DCF tripping, observe final steam pr. And
temperature and if require isolate attemparator.
 Reduce PA / SA flow to control bed temp.
 Check PA header pr. If it is less increase it.
 Control furnace draft and drum level.
 Check for reason of DCF tripping.
 Check electrical fault or emergency stop push button &
restart coal feeder.
 Check VFD fault, if any.
 Restart coal feeder after checking cause of Boiler tripping &
put the burner in service.
 Take burner support according to requirement.
 If the problem persists for longer time and pressure drops,
reduce load on turbine.
 10. APH TUBE FAILURE

A. CAUSE :-
 Erosion of tube.
 Corrosion of tube.
B. EFFECT :-
 Flue gas temp after APH will fall down.
 Increases in O2 percentage at ESP inlet.
 PA / FD Fan overloaded.
 Bed temp may be increased.
C. ACTION :-
 Control flue gas temp by passes APH.
 Reduce coal feeding to maintain O2 percentage.
 Control bed temp.
 If leakage of tubes are more stop the boiler and plug /
replaced.
 11. LOSS OF FANS

I. ID FAN

A. CAUSE :-
 Electrical motor protection
 Fan bearing temp becomes high high
 Motor bearing temp becomes very high
 Drive fault (MCC fault)
 Boiler trip
B. EFFECT :-
 Furnace may get pressurized
 Boiler will trip on boiler furnace pressure high.
C. ACTION :-
 Check emergency or field stop.
 Rectify electrical fault, if any.
 Check cause for boiler trip & normalize it.
 Check fan / motor-bearing temp.
 Restart I.D. Fan after checking cause of tripping and
taking corrective actions.
 Cut down air flow by operating FD dampers.
 Slump two compartments.
 Reduce load on turbine according to requirement.
 II. P.A. FAN
A. CAUSE :-
 Electrical motor protection.
 Fan bearing temp. becomes high high.
 Motor bearing temp. becomes very high.
 MCC fault.
 Boiler trip.
 Run feed back off.
 ID Fan trip.
B. EFFECT :-
 Boiler will trip on
 Furnace draft low
 P.A. flow low.
C. ACTION :-
 Rectify electrical fault, if any.
 Check cause for boiler trip and normalize it.
 Check fan / motor-bearing temp.
 Restart the P.A. Fan after checking the cause of tripping
and taking corrective actions.
 Check that whether all DCF got tripped or not. Otherwise
stop them immediately.
 Reduce the load on turbine according to requirement
 See that the standby fan is started. Otherwise start it and
increase the PA header pr.
 Check PA lines for jamming and clear them accordingly.
 III. FD FAN :-

A. CAUSE :-
 Electrical motor protection.
 Fan bearing temp becomes high high.
 Motor bearing temp becomes very high.
 MCC fault.
 Boiler trip.
 Run feed back off.
 I.D. Fan trip.
 PA Fan trip.
B. EFFECT :-
 Boiler will trip on low furnace draft.
A. ACTIONS :-
 Rectify electrical fault, if any.
 Check cause for boiler, trip & normalize it.
 Check fan / motor-bearing temp.
 Stop coal feeding.
 Reduce load on Turbine according to requirement
 Observe Bed temperature
 Restart the FD Fan after checking the cause of tripping and
taking corrective actions
 12. SUPER HEATER TUBE FAILURE :-

A. CAUSE :-
 Sustaining high metal temp due to water wall slugging or
inadequate steam flow and high gas temp during hot start.
 Erosion on tubes due to high excess air.
 Blocked tubes.
 Starvation of tubes.
 Salt deposition due to high water level in drum. Poor quality
of spray water.
B. EFFECT :-
 Hissing noise notices.
 Flue gas temp drops.
 High feed water consumption compared to steam flow.
 Over loading on I.D. Fan.
 Erosion of other tubes and damages to other APH tubes.
C. ACTION :-
 As soon as leakages noticed start reducing the load and trip
the boiler.
 Listen the SH region for steam leakage.
 Try to locate leakage through manholes before the boiler is
depressurized.
 13. HIGH SUPER HEATER TEMP

A. CAUSE :-
 High excess air.
 Low feed water temp HP Heater not in service at constant
firing / load.
 Sudden increase in firing rate to increase steam pressure.
 In adequate spray.
 Lodging of soot on the water walls considerably.
B. EFFECT :-
 Rise in (+ve) positive turbine expansion.
 Creep rate increase in tube metal, turbine parts, steam
piping.
C. ACTION :-
 Check feed water temp. If HP heaters are available, put in
service and if not reduce the load.
 Slow down firing rate.
 Reduce excess air, if more.
 Check attemparator control valve position in DCS and in
field, Take attemparator by – pass into service.
 Increase load on boiler.
 Observe the TG inlet steam temperature.
 Ensure that none of drum safety valve has popped.
 14. LOW SUPER HEATER TEMP. :-

 CAUSE :-
 Dirty super heater
 Inadequate air flow.
 High Spray
 Too high feed water temp.
 Sharp increase in load and pressure drop.
 High Drum level.
 EFFECT :-
 Turbine expansion may be negative.
 May induce thermal stresses in S.H.
C. ACTION :-
 Check air flow – increase, if necessary.
 Isolate attemparator and check for passing/opening of attemparator
by – pass..
 Check feed water temp.
 Avoid sharp rise in load to boiler pressure drop.
 If, it is due to high drum level – allow unit to trip and open main
steam drains.
 If main steam temperature drop takes place open steam pipe drains.
 Observe constantly the TG inlet steam temperature. Trip the turbine /
prime mover when steam temperature falls.
 Reduce load on boiler.
 Check bed temperatures and increase coal feeding accordingly.
 Check for jamming of coal hopper, PA lines and clear them
accordingly.
 Take burner support if required.
 Ensure that DCF chain is rotating (no shear pin failure).
 Ensure that air flow is sufficient.
 Drain bed material slowly, if bed height is more.
 15. BED TEMP. HIGH :-
A. CAUSE :-
 High CV and low ash coal used.
 Low P.A. flow / FD flow
 Sudden change in load
 Faulty bed temp thermocouple.
 Ash recalculating system trouble

B. EFFECT :-
 Chances of clinker formation
 Chances of refractory failure
 Chances of screen tube failure
C. ACTION :-
 Control bed temp by recirculation ash through
recirculation feeder.
 Charge bed material if bed height permits.
 Increase P.A. flow up and increase FD flow.
 Constantly observe the wind box pr.
 Reduce the load by cutting coal feeder.
 Coal feeders trip, if temp rises above limit and allow
boiler to trip, if temp exceeds beyond safe limit to
save bed from clinker formation.
 Check the bed temp thermocouple.
 Check for wind box damper position.
 Stop the boiler if temperatures still not controlled.
 16. BED TEMP LOW :-

A. CAUSE :-
 High PA with respect to load / high FD flow
w.r.t. load.
 Low CV high ash coal used.
 Coal interruption or coal feeder trips or
overfeeding of coal into furnace.
 Recirculation ash feeder speed may increase.
 Faulty bed temp. Thermocouple.
 Water tube / screen tube / evaporator tube failure.
B. EFFECT :-
 Boiler steam flow will reduce.
 Super heater temp drops.
 Furnace draft will fluctuate.
C. ACTION :-
 Reduce P.A. Fan flow, if excessive / reduce FD. flow, if
excessive.
 Reduce speed of recirculation ash feeder.
 Stop bed material supply, if running.
 Check bed temp thermocouple.
 Check any leakage sound from furnace.
 Check coal feeder and coal supply.
 17. PSH O/L steam temperature high

 Increase load on boiler.

 Minimize furnace draught.
 Check the position of overfeed secondary air dampers and
open them.
 Regulate air flow according to requirement.
 Increase bed height.
 Meanwhile confirm that the temperature indication is
correct (Attemperator flow will increase)
 18. Economizer O/L FW temperature high

 Increase load on boiler.

 Reduce Economizer I/L feed water temperature.
 Minimize furnace draught.
 Check the position of overfeed secondary air
dampers and open them.
 Regulate air flow according to requirement.
 Increase bed height.
 Meanwhile confirm that the temperature
indication is correct.
 19. High negative draught

 Confirm that the draught indication is correct.

 Check and control ID fan speed.
 Check wind box dampers position.
 Check ID dampers position.
 Check FD dampers position.
 Check APH online and by – pass dampers position.
20. Hot bed material leakage from PA lines or
bed ash drain/Back fire in PA lines

 Observe bed temperatures constantly and charge

bed material if required.
 Cut down coal feeding to that compartment, let the
bed temperature be drop down and close wind box
damper.
 Check that air damper of that line is open.
 Clear that line if the leakage is from vertical
portion.
 If the leakage increases further, stop the boiler.
 21. O/L steam pressure too low

 Check for passing or malfunctioning of Boiler safety

valves.
 Check for abnormal sound from furnace.
 Check for malfunctioning of Dumping control valve and
PRDS control valve.
 Check and increase the feed water temperature.
 If pressure goes down further and frequency drops, reduce
load on turbine.
TURBINE EMERGENCIES
 TURBINE EMERGENCIES

• Turbine trip
• Load throw off
• UAT trip
• CEP trip
• Hotwell level high
• Hotwell level low
• Vacuum drop
• Fire/smoke at turbine area
• Turning gear trip
• Oil temperature high
• Bearing temperature high
• Bearing vibration high
• Steam pressure high after first stage
 Turbine trip (sharing mode)

 Safeguard the running unit (Reduce load on turbine if

required and Ensure that CWP, BFP, ACWP, CT Fan,
Inst.air compressor are running)
 Cut down proportionate coal feeding in boilers.
 Observe boiler drum level and take steps accordingly.
 Control steam pressure by operating PRDS and dumping
control valves.
 Start AOP, JOP, TTG.
 Investigate the reason of tripping.
 Don’t switch on PEF until unless it is reset and load
shedding is switched – off.
 Turbine trip (Non – sharing mode)
 Safeguard the running unit (Reduce load on turbine if required
and Ensure that CWP, BFP, ACWP, CT Fan, Inst.air
compressor are running)
 Take grid supply after ensuring Generator breaker has opened.
 Observe boiler drum level and take steps accordingly.
 Control steam pressure by operating PRDS and dumping
control valves.
 Ensure that extraction MOV is closed.
 Start AOP, JOP, TTG.
 Investigate the reason of tripping.
 Don’t switch on PEF until unless it is reset and load shedding
is switched – off.
 Maintain hotwell level and ensure that CEP is running.
 Load throw – off
 Check turbine speed, if it is at alarming level and is
increasing further, trip the turbine.
 Observe drum level.
 Slump compartments in boiler according to the amount of
load thrown off.
 Take PRDS into service if both extractions are out of
service.
 Regulate dumping steam according to dumping header
temperature and condenser vacuum.
 Check for reason of load throw – off.
 If the load throw – off occurs because of any breaker
opening, check thoroughly before closing it.
 CEP trip

 Ensure that standby pump has taken over.

 Check for reason of tripping.
 Check hotwell level and if it is low, take make – up water
into hotwell.
 Open hotwell re – circulation valve fully.
 Check for passing of condensate valve B or C and isolate
them accordingly.
 If the tripping is because of overload, check for mechanical
jamming of pump.
 Hotwell level

A. Hotwell level high

 Ensure that standby pump has taken over.
 Check running CEP (s) load.
 Close hotwell re – circulation valve.
 Check position of condensate valve B or C and operate
them accordingly.

B. Hotwell level low

 Take make – up water into hotwell.
 Open hotwell re – circulation valve fully.
 Check for passing of condensate valve B or C and isolate
them accordingly.
 Vacuum drop

 Check gland steam pressure.

 Check CW temperatures.
 Check hotwell level.
 Check the running ejector.
 Check for air ingress from all vacuum related lines and
valves.
 Cut down dumping steam.
 Charge standby ejector if the rate of drop is more.
 If the rate of drop is more, reduce load on turbine.
 Fire/smoke at turbine area

 Ensure that vapour extraction fan is running if the fire is

because of oil leakage from any bearing.
 Use CO2 fire extinguisher in case of minor oil and
electrical fires. Don’t use water or other type of fire
extinguishers.
 In case of major fire, first isolate the source (trip the turbine
and isolate generator from electrical circuit) and then
quench it.
 Turning gear trip

 Ensure that jacking oil pressure is sufficient.

 Ensure that lube oil pressure is sufficient.
 Put turbine on manual barring gear.
 Check for reason of turning gear trip.
 Oil temperature high

 Ensure that the CW temperatures are not on higher

side (All CT fans are running).
 Stop TOPP if it is running.
 Check oil level in Main oil tank.
 Provide external cooling arrangement.
 Ensure that oil temperature controller is working.
 If the bearing temperatures start increasing, trip the
turbine immediately and provide external cooling
arrangement for bearings.
 Bearing temperature high

 Charge bleed steam.

 Check oil temperature.
 Check oil level in Main oil tank.
 Ensure proper oil flow to the bearing.
 Check axial shift.
 Provide external cooling arrangement.
 Reduce load on turbine if temperatures goes on rising.
 Bearing vibration high

 Confirm that the signal is correct and is matching with

Bently – Nevada vibration monitoring system.
 Confirm the same in field physically.
 Ensure proper oil flow to the bearing.
 Check casing temperature difference.
 Reduce load on turbine if vibration goes on rising.
 Steam pressure high after first stage

 Reduce load on turbine if pressure is at alarming level.

 Reduce bleed steam.
 Check control valve position and turbine speed.
 CWP trip/ Discharge header pr. low

 Ensure that standby pump has taken over.

 Monitor condenser vacuum.
 Reduce load on TG.
 Cut down dumping.
 Investigate the reason for tripping.
 If both the CWP tripped and standby has not taken over
because of any common problem, trip both TG and isolate
all steam inputs to the condenser.
 Inst. Air compressor trip/Inst. Air pr. low

 Ensure that standby compressor has taken over.

 Check conserveir O/L air pr.
 Monitor boiler drum level, furnace draft, CWP
discharge header pr., FD control dampers position
constantly.
 Ensure that running compressor is fully loaded.
 Check for choking of dryer filters.
 Ensure that both dryers power supply is ON.
 Check for leakages in the system.